Method and apparatus for molding shoe inserts

ABSTRACT

A method and apparatus are provided for relatively convenient and efficient production of custom molded inserts for shoes. The apparatus utilizes a molding pillow arrangement, upon which a user stands during use. The molding pillow arrangement has a composite construction including a first resilient layer, a middle resilient layer and a bottom support layer. The bottom support layer preferably includes a generic arch curve therein. The upper resilient layer is formed from a relatively soft foam, and thus molds around a user&#39;s feet. The middle layer is resilient, but relatively hard by comparison to the upper layer. The middle layer provides for a relatively firm cushion underneath the user&#39;s foot, facilitating contouring of a molded insert to the bottom of the user&#39;s foot. Preferably, at least the upper cushion portion of the molding pillow arrangement comprises left and right cushions, independently moldable with respect to a user&#39;s left and right feet. A preferred insert construction for use in association with the method and apparatus is provided.

FIELD OF THE INVENTION

The present invention relates to insoles and in particular to custominsoles for support and cushioning of a user's feet. The inventionspecifically relates to a method and apparatus for molding such insoles.

BACKGROUND OF THE INVENTION

Activities which concern locomotion of the human body, such as walking,running and involvement in various athletic activities, place stress onthe bones and joints of the leg and foot. These stresses can be quitegreat, and can be harmful if the bones and joints of the foot are notsupported properly.

One method of providing support for the foot is through the utilizationof standardized or universal insole cushions and arch supports. Whilethese do provide some support and comfort, due to their standardizationand lack of customization they are inadequate for many uses. Inparticular, since the shape of feet vary greatly, as well as people'sweight, weight distribution, leg structure and knee structure,standardized inserts and arch supports lack universal utility withoptimized results.

Custom insole systems have been developed. An example is the FOOT TECHCustom Insole system developed by Foot Technology, Inc., the assignee ofthe present invention. Generally, the FOOT TECH system involves theconstruction of a mold of the user's foot. The mold is typically kept bythe manufacturer and is used to custom mold shoe inserts. Such insertsmay include, for example, a custom molded arch support, a heel sectionand a toe section.

Such custom methods and arrangements have been available for aconsiderable period of time and have been highly effective. However, aproblem with such methods is that they are generally inconvenient to theend user and are relatively expensive. Thus, while they suit theprofessional athlete fairly well, they are generally unacceptable tomany lay persons.

More convenient and inexpensive custom molding systems have beendeveloped. One such arrangement is known as the CONFORM'ABLE system fromSIDAS, apparently available through Bio-Dynamics, Inc. of Concord, N.H.03301. This system is generally used for mountaineering-type footwearand ski-wear. The insole is a thermal-molded product. The product isheated until it becomes moldable, and then it is stepped upon by theuser. As the insole cools, it forms to the user's feet. Generally, thesystem involves placing the insole upon a foam molding pad having abuilt-up arch support portion. The molding pad permits the heated insertto conform to the user's feet. The arch support molds an arch curve intothe insert. An advantage to this arrangement is that the inserts can beformed in a matter of minutes; for example, in a shoe store or asporting goods store.

Another insole molding system is available from Peterson Laboratories ofLake Placid, N.Y. Peterson offers a BIOCOMFORT system in which an insertis molded, upon a pillow, in the shoe store. The Peterson pillow isdesigned such that a forward portion of the foot rests upon very littlecushion, during molding, whereas the heel portion of the foot is on anapparently soft, considerably built-up pillow. Peterson also has offereda related BIOTHOTIC system in which an impression of the foot is moldedin a low density polyethylene sheet. The sheet material, after molding,apparently is used as a core for a shoe insert, which is latermanufactured.

These and similar methods are directed to the development of a methodfor conveniently, relatively rapidly and inexpensively forming a custominsert for shoes. The methods generally involve attempts to solve thetwo interrelated problems of:

1. Providing for preparation of a custom insert in a relatively shortperiod of time, at low expense; and

2. Providing of a molding method by which a properly supportive insertis formed.

Various insert materials have been developed, to aid in molding andoperation of the finished product.

In general, while available methods approach desirable low-cost, easilymade custom inserts, there has been need for improvement in the generalareas outlined above. The present invention in particular addressesthese problems.

OBJECTS OF THE INVENTION

Therefore, the objects of the present invention are: to provide a methodand apparatus for molding shoe inserts; to provide a preferred insertfor relatively easy and inexpensive molding by such a method andapparatus; to provide a method of molding shoe inserts involving theutilization of a multi-layer molding support for the user; to provide apreferred such a molding support comprising an upper layer of a firstresiliency and a lower layer of a second resiliency; to provide such anapparatus wherein the upper resilient layer comprises a soft foam andthe second lower layer comprises a more firm foam; to provide such anarrangement wherein a user steps upon a left set of cushions with onefoot and a right set of cushions with another foot during typical use;to provide such an arrangement wherein the upper soft foam layers aresufficiently soft to substantially wrap around a user's foot duringmolding; to provide such a method and arrangement wherein the lower,more firm, layer provides a substantially firm yet cushioned supportunderneath the more soft layer, for efficient molding; to provide aparticularly effective stand apparatus for use in implementation of sucha method; and, to provide such a method, apparatus and insert which arerelatively inexpensive to produce and use, and which are particularlywell adapted for the proposed uses thereof. Other objects and advantagesof this invention will become apparent from the following descriptions,taken in connection with the accompanying drawings, wherein are setforth by way of illustration and example certain embodiments of thepresent invention.

SUMMARY OF THE INVENTION

A method is provided for forming custom insoles. The method generallyinvolves the use of a molding pillow arrangement and moldable inserts.

In a typical operation, the molding pillow arrangement is oriented sothat it can be stepped upon by a user. Preferably, the pillowarrangement comprises first and second composite pillow members orportions, each having two cushion or pillow layers and a rigid supportlayer.

For the preferred embodiment, each of the two pillow members has a rigidlower support formed from styrofoam or the like. The lower supportpreferably has a constant lateral cross-section and a rear to frontdownward curve. The downward curve generally corresponds to a genericarch curve and conveniently provides for a molded insole with a raisedheel utilizable, comfortably, in shoes with or without raised heels.

For the preferred embodiment two cushion layers are positioned above thelower support layer. The resiliency and/or firmness of the two cushionlayers preferably differ from one another, in a preferred manner.Specifically, the uppermost cushion layer is softer than the central orlower cushion layer. For the preferred embodiment, each of the cushionsis of a constant cross-section both laterally and from front-to-rear. Inuse they are supported with a curved shape, as a result of resting uponthe lower curved rigid support portion.

As a result of having a relatively soft structure, the upper cushion orlayer operably wraps substantially around the foot of a person whostands thereon. This causes deformation of a moldable insert positionedbetween the user's foot and the cushion, to comfortably wrap around thefoot of the user and mold the insert into conformity with the shape ofthe user's foot. In particular, this arrangement provides for arelatively deep heel portion and a well-defined arch support section.

As previously described, the central or lower cushion layer of thepreferred embodiment is firmer or of greater resiliency than the upperlayer. This relatively firm layer cushions a user standing upon thepillow arrangement and generates a good molding of the bottom of theinsert to the bottom of the user's feet, particularly in the arch andtoe areas. The relatively firm construction of the lower cushion layerfacilitates weight distribution.

In the preferred embodiment the upper and lower cushion layers areseparable from one another. As a result, a technician can slip his orher hand, or an implement, between the two layers during a moldingoperation. In this manner the position of a foot of a person standingupon the cushions can be adjusted. Further a molded shape of an insertcan be modified, enhanced and controlled.

As previously indicated, for the preferred embodiment the molding pillowarrangement is separated into first and second sides or halves.Generally, the user stands upon the arrangement with one foot on onehalf and the other foot on the other half. At least the upper cushion,and preferably both the upper and the central cushions, are disjointedfrom one another along the line separating the two halves. As a result,the two upper cushions are free to form and mold about each of theuser's feet, independently.

In the preferred embodiment, for typical use the pillow arrangement isoriented within a stand. The stand includes arm rests and aknee-positioning mechanism. The knee positioning mechanism can beutilized to selectively orient a person standing upon the pillows,before molding is undertaken. The arm supports help the user to securelystand upon the yielding cushions.

The preferred knee positioning mechanism is a cushioned bar which isadjustable vertically, and also toward and away from a user. This systemis advantageous since it can be rapidly adjusted by a technician, andcan comfortably accommodate a variety of users.

In a typical use, the left and right molding cushions are positionedwithin a recess in the stand. The user stands upon the pillows and hisor her feet are appropriately oriented upon the pillows. The user thensteps off of the pillows and a heated, deformable, insole insert isplaced on each of the pillow members.

The user then steps upon the inserts, repositioning his or her feet inthe previously determined preferred orientation according to markers onthe pillows and through use of the knee-positioning mechanism. The userremains standing upon the moldable inserts until molding is completed.This generally takes two to five minutes. The user then steps off of themolded inserts, the inserts are trimmed as necessary and are thenreadily usable by insertion into the user's shoes. During the moldingoperation, the technician may insert a hand or object between thecushions to selectively adjust positioning of the foot or molding of theinsert.

Preferred inserts according to the present invention are compositestructures and may be of varying types. An often preferred compositeincludes a lower thermoplastic layer which is soft, and flexible butwhich retains its molded shape at and near room temperature and whichbecomes relatively moldable when heated. The next layer may preferablyinclude a rigid material such as a piece of polyvinylchloride plasticarch support which can be molded after having been heated. The nextlayer above the moldable portion(s) is preferably a cushioning orshock-absorbing layer, generally comprising a polymeric cushion or thelike. Above the shock absorbing layer, and typically adjacent the user'sfeet, is located a top member comprising nylon or the like which permitsthe user's foot to breathe and which can readily absorb moisture andprovide a comfortable surface. Other cushion layers may be utilized, asdesired. Further, while rigid arch supports may be prescribed, they arenot required in all instances.

In some applications of the present invention the composite insoleinsert may include means providing for the mounting of a medical supporttherein. This can be accomplished by providing for separability betweenseveral of the composite layers, and by providing an insert positionabletherein.

The drawings constitute a part of this specification and includeexemplary embodiments of the invention, while illustrating variousobjects and features thereof. In some instances relative component sizesor material thicknesses may be shown exaggerated, for clarity.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary, exploded perspective view of an apparatusaccording to the present invention, with portions broken away to showdetail.

FIG. 2 is a fragmentary rear perspective view of the apparatus shown inFIG. 1, with a user standing thereon.

FIG. 3 is an enlarged fragmentary cross-sectional view taken generallyalong line 3--3, FIG. 2.

FIG. 4 is an enlarged fragmentary side cross-sectional view takengenerally from the orientation of line 4--4, FIG. 1, prior to a userstepping thereon; phantom lines generally indicating deformation from auser's foot also shown in phantom lines.

FIG. 5 is an enlarged exploded view of a composite insert usableaccording to the present invention in the molding process thereof.

FIG. 6 is an enlarged perspective view of a molded insert made accordingto the present invention.

FIG. 7 is a perspective view of an insert according to the presentinvention made with a medical split therein, phantom lines indicatingportions out of view.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As required, detailed embodiments of the present invention are disclosedherein. It is to be understood that the disclosed embodiments are merelyexemplary of the invention, which may be embodied in various forms.Therefore, specific structural and functional details disclosed hereinare not to be interpreted as limiting, but rather as a basis for theclaims and as a representative basis for teaching one skilled in the artto variously employ the present invention in virtually any appropriatelydetailed structure.

The reference numeral 1, FIG. 1, generally designates an overallapparatus utilizable in association with the principles of the presentinvention. The apparatus 1 comprises a stand 2 having a molding pillowarrangement 3 therein. Specific advantages, according to the presentinvention, are obtained from the particular molding pillow arrangement 3described and shown.

In FIG. 1, apparatus 1 is shown in a typical orientation for use inmolding insoles. In FIG. 1, composite insoles 5 are shown oriented formolding. According to the present invention, the insoles 5 are heated,until moldable, and are positioned on the pillow arrangement 3, asshown. A user then stands upon the insoles 5 molding same. The usertypically remains standing upon the insoles 5 until the insoles 5sufficiently cool to a molded state in which they will remain.

Referring again to FIG. 1, stand 2 includes a base or pedestal portion10, left and right handrail extensions 11 and 12 respectively, and aknee positioning mechanism 15.

The right handrail extension 12 comprises first and second upwardextensions 18 and 19 with hand rail 20 extending therebetween.Preferably hand rail 20 is supported at a convenient height for use insteadying a person standing upon pillow arrangement 3. Generallyhandrail 20 is typically positioned at a height between hip and waistlevel for most users.

Similarly, left handrail extension 11 comprises upward extensions 21 and22 and hand rail 23.

Base 10 includes a front portion 25, a rear portion 26 and left andright side portions 27 and 28 respectively. The base 10 includes anupper recess 30, defined by border or curb 31, in which molding pillowarrangement 3 is received during use. Recess 30 insures securepositioning of members of the molding pillow arrangement 3, inhibitingtheir unintended movement during use.

Knee positioning system 15 includes an adjustable bar 36. The bar 36includes a cushion 37 thereon, which is pressed against a user's kneesduring a molding operation. The cushion 37 has an outer covering 38 ofnylon or the like, for convenience.

The bar 36 is vertically positionable and is movable toward and awayfrom a user. Also, the bar 36 is rotationally adjustable. For thepreferred embodiment illustrated in FIG. 1, the bar 36 is verticallyadjustable, by means of clamps 39, in slots 40 and 41. The bar 36 can bemoved toward and away from a person standing within appartus 1, by meansof adjustment of clamps 42 in slots 43 and 44. Rotational adjustment isalso facilitated by clamps 42.

The mechanism for adjusting knee positioning is preferred overconventional systems for numerous reasons. First, it can be adjustedforward and back. Secondly, it can be rapidly adjusted. Also, both kneescan be quickly adjusted and are comfortably supported. Adjustment inpositioning of a user's knees can be used to selectively orient theposition of and weight distribution on a user's feet, as a user standsupon molding pillow arrangements 3. As a result, a selected,reproducible, position for a user can be set, prior to placing amoldable insert underneath a user's feet. This will be further describedbelow.

Referring again to FIG. 1, non-slip mats 55 and 56 are shown mounted onsides 27 and 28. During operation of apparatus 1 should it becomenecessary for a user to straddle recess 30, non-slip pads 55 and 56facilitate security and safety.

Referring to FIG. 1, molding pillow arrangement 3 for the preferredembodiment comprises first and second pillow members 59 and 60. Members59 and 60 comprise a left pillow member 59 and a right pillow member 60.For the preferred embodiment the two pillow members 59 and 60 areindependent of one another, both being positioned in recess 30.

Pillow members 59 and 60, for the preferred embodiment, are compositemembers with substantial advantages being obtainable from the compositearrangement. Referring to FIG. 1, member 59 is shown comprising first,second and third layers 65, 66 and 67 respectively. Layer 67 is arelatively rigid base having an upper surface 70. Member 67 has asubstantially constant lateral cross-section, FIG. 3. However, it has adownwardly slanted curve therein, from rear to front, which supports thecontour of the longitudinal arch areas with respect to heel height.

In FIG. 4, a side cross-sectional view of pillow member 60 is shown.Pillow member 60 includes first, second and third layers 75, 76 and 77respectively. Member 77 is a rigid layer substantially identical tomember 67, FIG. 1. Arch curve 78 is viewable in FIG. 4 slopingdownwardly from a rear heal portion 79 to a front toe portion 80 ofrigid member 77. For the preferred embodiment, curve 78 approximates anarch curve for a person having a shoe with a slightly raised heel.Typically the heel area is raised over the toe area a total of betweenabout one-quarter and three-quarter inches, and preferably is raisedabout one-half inch.

Preferably, members 67 and 77 are easily formable from a relativelyinexpensive, available material. For the preferred embodiment, members67 and 77 are formed from styrofoam. As a result, members 67 and 77 donot substantially compress when stood upon by a user. Preferred members67 and 77 may be cut from a single rectangular piece of styrofoam, withcutting between side edges simultaneously forming both pieces. As aresult of being formed from relatively inexpensive styrofoam, members 67and 77 can be readily discarded and/or replaced as necessary.

Referring again to FIG. 1, layers 65 and 66 are compressible layers.That is, each of layers 65 and 66 compress when they are stood upon by auser. Preferably each is formed from a foam material such as apolyurethane foam rubber or the like. Layers 65 and 75 are formed from arelatively soft foam with advantages resulting therefrom, as will bediscussed in more detail below. Members 66 and 76, the central or lowermembers, are formed from a foam which is harder or firmer than layers 65and 75. The provision of a pillow member having upper and lowerresilient layers of different resiliency, with the upper layer beingsofter, yields particular advantages according to the present invention.

Referring to FIG. 1, upper layer 65 includes an outer covering 81 formedfrom nylon or the like. An analogous covering may be used on the lowerlayer 66. The covering provides an easily cleanable covering for thecushion(s). Further, it may be readily marked or imprinted, as forexample with markings 82 utilizable to selectively position the user'sfoot and the insert 5. Another advantage to covering 81 is that itprotects foam 65 from damage and further provides a protective coatingfor the hot moldable insert 5.

Advantages obtained from the relatively soft upper layer of foam will beunderstood by reference to FIGS. 2, 3 and 4. Referring to FIG. 2, upperlayers 65 and 75 are shown laterally spaced from one another, with auser 85 standing thereon. Since the foam of the upper layers isrelatively soft, the user's feet will substantially sink therein, withthe foam wrapping substantially up and around the user's foot. Layer 65can wrap around the user's left foot, and independently layer 75 canwrap around the user's right foot, since the two foam members 65 and 75are completely separate from one another. When deformable inserts areplaced between the user's feet and cushions 65 and 75, the inserts willbe readily molded up around the user's foot, as a result of the softfoam. Thus, a relatively deep heel portion will be formed in the insert,as well as a well-defined arch portion and an edge line wrappingupwardly around the user's foot.

As previously explained for the preferred embodiment, the middle layers66, 76 of the cushions 59 and 60 are also compressible, but are formedfrom a foam which is somewhat harder than the upper layer. This forms acompressible base upon which a user can stand. The relatively highresiliency of middle layers 66, 76 leads to some resistance to thewrapping around illustrated by upper layers 65, 75. Thus, the middlelayers 66, 76 firmly push upwardly against the bottom of the user'sfeet. This pushes the upper cushion 65 and 75, and any deformable insertpositionable between cushions 65 and 75 and the user's feet, up towardthe bottom of the user's feet. The result is a molding of contours intothe molded insole which conform well to the bottom of the user's feet.An advantage to the firmer cushion is that it facilitates good weightdistribution during molding.

As a result of the two different resiliencies of cushions used for eachcomposite pillow member, and the utilization of an upper relatively softcushion member, an effective mold is provided for the user's feet. Themold is readily usable in association with a moldable insert placed uponupper surfaces of pillows 59 and 60, and is quickly prepared for reuse.The upper, soft, layer forms a relatively deep heel cup, and good archwrapping and a side edge to the molded insert. The firmer lower cushionsupports the weight of the user while generating contouring in thebottom of the insert.

It is noted that while the preferred embodiment has upper and lowercushions (65 and 66; or, 75 and 76) which are completely separable, theupper and lower cushions could be attached or be integral with oneanother. However, advantages result from their separability or at leastpartial separability since, during molding, a technician can insert ahand or object between the two layers to effect or adjust molding, orthe position of a user's foot.

Referring to FIG. 5, an insole insert 90 utilizable, as shown for insert5, FIG. 1, in association with the present invention is illustrated.Insert 90 is a composite member having: a lower thermoplastic layer 91;an arch and heel support member 92; a cushion layer 93; and, an upperprotective layer 94. While a variety of composite structures might beutilized in association with the principles of the present invention,the structure of FIG. 5 is convenient and preferred in many uses.

Referring again to FIG. 5, lower layer 91 is a thermoplastic layer whichmay be readily molded in an apparatus according to the presentinvention. Layer 91 preferably comprises a soft plastic material whichhas substantial memory at room temperature and typical use temperatures,to provide contouring for the insert 90. When the material from whichlayer 91 is formed is heated substantially, as for example in aconvection oven at 250° F., for several minutes, it becomes pliable andmoldable. A preferred thermoplastic material for layer 91 is VINYLPLEX apolyvinyl chloride material available in a strip form from AlphaPlastics of St. Louis, Mich. 49990. The strips of VINYLPLEX are madefrom GEON 87438, a B.F. Goodrich polyvinylchloride product.

In some instances a fairly rigid arch support may be prescribed. Thepreferred insert portion 92, FIG. 5, is a somewhat triangularly shapedpiece of material which is not as soft or flexible as thermal plasticlayer 91 but which is deformable and moldable, when heated, to form anarch support and heel cup. Preferably insert 92, as suggested, is formedfrom material which at room temperatures and typical use temperatures issufficiently rigid to provide substantial support. A preferred materialfor insert 92 is a plastic material such as a polyvinylchloride which,when heated along with thermoplastic layer 91, becomes sufficientlypliable to be moldable to conform to a user's heel and arch and furtherwhich readily cools to a molded, relatively rigid, construction.

For the insert illustrated in FIG. 5, layer 93 comprises a shockabsorbing layer of foam or the like. Preferably layer 93 is formed froma relatively durable synthetic material. It may be of a variety ofthicknesses, depending upon the cushioning effect desired for the insoleinsert.

Upper layer 94, FIG. 5, comprises a protective layer of a material suchas nylon or the like which can be readily cleaned, which will becomfortable for a user within that user's shoes, and preferably whichwill absorb moisture draining same away from the user's feet andpermitting the user's feet to breathe somewhat.

In a typical application, layers such as layers 91,92,93 and 94 areformed into a composite insert such as insert 5, FIG. 1. The insert isthen heated, until it becomes moldable, in a convection oven or thelike. Preferably, the materials are chosen such that insert 5 becomesmoldable when heated in a convection oven at about 250° F. for about twoto five minutes. Thus, the insert will be warm, but handlable.

Referring to FIG. 4, the heated insert 5 is positioned on top of anappropriate cushion, such as cushion 75. When a user's foot 100 ispositioned thereon, under the weight of the user's foot the insert 5will be depressed into, and is molded by, the upper relatively softcushion 75 in association with the lower relatively hard cushion 76.Arch curve 78 provides for a raised heel in the molded insert 5, thusproviding an arrangement comfortable with either flat shoes or shoeswith raised heels.

Referring to FIG. 6, a molded composite insert 105 is depicted.

Inserts having a variety of composite structures may be utilized inassociation with many of the principles of the present method, althoughthe arrangement of FIG. 5 having two moldable layers 91 and 92 ofdifferent resiliency offers advantages in some applications. Generally,the layers may be formed into a single unit by use of adhesives or thelike. These units can be readily formed into left foot and right footunits, if desired. In FIG. 6 a molded left foot unit is depicted.

In some applications of the present invention, it may be desirable toprovide a medical support such as a metatarsal support within theinsert. Referring to FIG. 7, an insert 110 is shown having a medicalsupport 111 positioned therein. The arrangement illustrated in FIG. 7will be referred to herein as a "medical split". The medical split showncomprises a composite structure 110 having an upper portion 113 and alower portion 114. Although the heel portions of members 113 and 114 areglued or adhered to one another, front portions thereof are separable orsplit, so that insert 111 can be easily positioned therein, eitherbefore or after molding. In this manner, the insert 111 can beselectively positioned for the particular patient involved. If desired,layer 113 can be attached to layer 114 by means of adhesive, aftermedical support 111 is positioned. This medical support 111 offersdistinct advantages not generally available from conventional system 5.

Typical operation of the present method will be understood by referenceto FIGS. 1-4. Referring to FIG. 1, for a preferred application apparatus1 is prepared with first and second molding pillows 59 and 60 positionedtherein, and with the arch curves slanted downwardly or toward the frontportion 25 of base 10. Recess 30 helps retain the cushions 65, 66, 75and 76 in position.

Markings 82 are provided on upper surfaces of relatively soft pillows 65and 75. The user stands upon pillows 65 and 75 with his or her feetappropriately positioned with respect to markings 82, to achieve properalignment with the downward arch curve. The markings can be utilized toaccommodate, for example, appropriate positioning of persons with feetof varying sizes. The user's knees are placed into association withcushion 37 and bar 36. The bar 36 is selectively oriented to positionthe user's legs, knees and feet in a preferred orientation. During thisprocess, the user can steady himself or herself through the use ofhorizontal rails 20 and 23.

Detail is not provided herein with respect to selection of anorientation of the user's feet, knees and legs. Theories and hypotheseswith respect to this may vary. Further, the particular orientationselected is not critical to application of the present invention as awide variety of orientations can be accommodated.

After appropriate positioning of knee support bar 36, the user can theneither step out of apparatus 1 or, if desired, can straddle pillowmembers 59 and 60 by stepping upon strips 55 and 56. Heated, prepared,inserts 5 are then positioned appropriately upon upper pillows 65 and75, with respect to markings 82, for that selected user. Prior to beingplaced upon pillows 65 and 75, inserts 5 will have been appropriatelyheated as to become moldable.

The user then steps downwardly upon moldable inserts 5, standing thereonand supporting themselves by rails 23 and 20, if necessary, while themolding process is completed. The markings 82 and knee positioningmechanism 15 can be used to reproduce the earlier selected position.Referring to FIGS. 2, 3 and 4, the relatively soft upper cushions 65 and70, and relatively firm lower cushions 66 and 76 provide for a desirablemolding of the insert 5 with respect to the user's feet, especially informing arch portions and heel portions. After several minutes, operableinserts 5 will have sufficiently cooled to form inserts, such as insert105, FIG. 6, having contours conforming to the user's feet. The userthen steps off of the apparatus 1, and the molded inserts are removedand trimmed as necessary. The inserts may then be placed in the user'sshoes, as custom insole supports and cushions.

If desired, an insert involving a medical split may be used. Under suchcircumstances, the medical support can be positioned either before orafter molding, as desired.

In some applications, the custom molded insert can be used to form abase or core around which a more built-up insert is provided. Forexample, a molded insert such as insert 105 may be used to form the coreof a larger insert utilized in a ski boot or the like. This could beaccomplished, for example, by taking molded insert 105 and addingcushioning or space-filling material to an underside thereof, tobuild-up a permanent or semi-permanent insert for a ski boot or thelike.

Referring to FIG. 3, for the preferred embodiment described and shown,the lower support members 67 and 77 are separate from one another, butare substantially identical. It will be understood that the two lowerrelatively rigid members 67 and 77 could be made integral with respectto one another, and further could be directly formed within base 10.However, the styrofoam arrangement described and shown is preferred andmembers 67 and 77 can be removed and replaced independently from oneanother, as desired.

Generally, middle layers 66 and 67, of the preferred embodiment, arecompletely independent from one another. As a result, they may wrapsomewhat around a user's foot, while providing firm support for theupper layer 65 and 75 respectively. While in FIG. 3 little suchdeformation is exhibited, it may be substantial under the certaincircumstances, depending in part upon the weight and size of the user.It will generally be advantageous to provide members 66 and 76 separatefrom one another in an apparatus according to the present invention.

According to the present invention, it is generally a requirement thatcushions 65 and 75, the upper cushions, be either completely separatefrom one another or joined in such a manner that they may independentlydeform as shown in FIG. 2 to wrap around a user's foot.

A variety of weights and resiliencies of cushions may be utilized inassociation with the principles of the present invention. Generally whatis required is a cushion material for the upper cushion which issufficiently soft as to provide for the pronounced wrapping effectillustrated in FIG. 3 and described herein. Further, generally what isrequired for the middle layers is a resilient material which is harderthan the upper layers and provides for a good firm effective lowersupport.

A preferred foam material for both layers is a polyurethane foam. Anexample is TEMPER FOAM® available from KGM (Kees Goebel Medical) ofHamilton, Ohio 45011. The preferred upper layer is pink TEMPER FOAM®, apolyurethane foam assigned KGM product code T-38. The density of suchmaterial is generally about 6.4 pounds per cubic foot with a tensilestrength of about 22 psi, an ultimate elongation of 218%, a ball reboundresilience value of 3.6%, an indentation force deflection (25% IFDvalue) of 156 IFD-Newtons, and a compression set Ct at 50% of 1%. Apreferred middle layer, also formed from TEMPER FOAM®, is a polyurethanefoam, available from KGM under product code T-41 with a density of about6.4 pounds per cubic foot, a tensile strength of about 36 psi, anultimate elongation of about 200%, a ball rebound resilience value ofabout 4.6% and an indentation force deflection (25% IFD value) of about223 IFD-Newtons. For the preferred embodiment both the upper layers 65and 75 and the middle layers 66 and 76 are about one inch thick.

While a variety of foams may be used as the upper and lower layers,generally preferred foam for the upper layer has: a tensile strength of14-30 psi; and a ball rebound resilience value of 3.0-4.0%. Preferredfoam for the lower layer has: a tensile strength of 31-40 psi; and, aball rebound resilience valve of 4.1-5.0%.

If a user's feet are too large for apparatus 1, FIG. 1, the moldingpillows 59 and 60 can be removed therefrom and placed upon the floor.Cushion extensions may then be placed in association with the members 59and 60, extending the length to handle a relatively large foot andinsert.

If the user is a person who has trouble standing, pillow arrangementssuch as 59 and 60 may be utilized in association with a variety ofsupport arrangements for the user, including ones wherein considerablesupport is provided for the user, leading to relatively little downwardforce or weight upon the feet. It will be understood that under suchcircumstances, variations in weight thickness and firmness of foam maybe desireable.

As previously suggested, advantages result from having upper and lowerfoam layers (ex. 65 and 66) which are separable from one another, so atechnicians hand or an object can be inserted therebetween duringmolding. While further advantages are derived for such a system whereinthe foam layers have different resiliencies as described, advantage fromseparability of lower and upper layers results regardles of the relativefirmness of the layers.

It is to be understood that while certain embodiments of the presentinvention have been illustrated and described, the invention is not tobe limited to the specific forms or arrangement of parts hereindescribed and shown.

What is claimed and desired to be secured by Letters Patent is asfollows:
 1. A support apparatus for use in molding an insert placedthereon to a user's foot, said support apparatus comprising:(a) an upperresilient layer of relatively soft foam material capable ofsubstantially molding about a foot of a person placed thereon; and, (b)a lower resilient layer of foam material; said lower resilient layerbeing substantially firmer than said upper resilient layer and beingcapable of providing a support substantially contoured to a bottom of afoot placed on said support apparatus;(i) said upper and lower resilientlayers: being separable from one another, enabling insertion of a membertherebetween; and, being constructed and arranged in a mannerfacilitating molding of said upper resilient layer, about a user's footat least partially independently of molding of said lower resilientlayer.
 2. A support apparatus according to claim 1 including:(a) a basemember positioned underneath said lower resilient layer; said basemember being substantially rigid and including an arch curve with araised heel.
 3. A molding pillow arrangement for use in molding aninsert placed thereon to a user's feet; said pillow arrangementcomprising:(a) a first foot support pillow member having an upperresilient layer of relatively soft foam material capable ofsubstantially molding about a first foot of a person placed thereon;said first foot support pillow member having a lower resilient layer offoam material, said lower resilient layer being substantially firmerthan said upper resilient layer and being capable of providing a supportsubstantially contoured to a bottom of a first foot of a person placedon said first foot support pillow member;(i) said upper and lowerresilient layers of said first pillow: being separable from one another,enabling insertion of a member therebetween; and, being constructed andarranged in a manner facilitating molding of said upper resilient layer,about a user's foot, at least partially independently of molding of saidlower resilient layer; (b) a second foot support pillow member having anupper resilient layer of relatively soft foam material capable ofsubstantially molding about a second foot of a person placed thereon;said second foot support pillow member having a lower resilient layer offoam material, said lower resilient layer being substantially firmerthan said upper resilient layer and being capable of providing a supportsubstantially contoured to a bottom of the second foot of a personplaced on said second foot support pillow member;(i) said upper andlower resilient layers of said second pillow: being separable from oneanother, enabling insertion of a member therebetween; and, beingconstructed and arranged in a manner facilitating molding of said upperresilient layer, about a user's foot, at least partially independentlyof molding of said lower resilient layer; (c) said first foot supportpillow member upper resilient layer being constructed and arranged to bemoldable about the person's first foot substantially independently ofmolding of the second foot support pillow member upper resilient layerabout the person's second foot.
 4. The molding pillow arrangement ofclaim 3 wherein each upper resilient layer comprises a polyurethane foamlayer having a tensile strength of between about 14 and 30 psi, a ballrebound resilience value of between about 3.0 and 4.0%, and wherein eachupper resilient layer is at least about one inch thick.
 5. The moldingpillow arrangement of claim 4 wherein said lower resilient layer of eachsupport pillow member comprises a polyurethane foam layer having atensile strength of between about 31 and 40 psi and a ball reboundresilience value of between about 4.1 and 5.0%.
 6. The molding pillowarrangement of claim 3 wherein:(a) said first foot support pillow memberincludes a lower rigid base portion having an arch curve and a raisedheel; and (b) said second foot support pillow member includes a lowerrigid base portion having an arch curve and a raised heel.
 7. Anapparatus for use in preparing custom molded shoe inserts; saidapparatus comprising:(a) a support apparatus having a base portion, anarm rail portion and a knee positioning mechanism;(i) said base portionincluding a pillow mechanism-receiving recess therein; (b) a moldingpillow mechanism positioned within said receiving recess and comprisinga left pillow arrangement and a right pillow arrangement; each of saidleft and right pillow arrangements including:(i) an upper resilientlayer of relatively soft foam material capable of substantially moldingabout a foot of a person placed thereon; and (ii) a lower resilientlayer of foam material beneath each upper resilient layer; said lowerresilient layer; being substantially firmer than said associated upperresilient layer and being capable of providing a support substantiallycontoured to a bottom of a foot placed on said pillow arrangement; and,(iii) said associated upper and lower resilient layers: being separablefrom one another, enabling insertion of a member therebetween; and,being constructed and arranged in a manner facilitating molding of saidupper resilient layer, about a user's foot, at least partiallyindependently of molding of said lower resilient layer.
 8. An apparatusaccording to claim 7 wherein said knee positioning mechanism includes aknee positioning bar vertically and horizontally adjustable forselective engagement with a user's knees.
 9. An apparatus according toclaim 8 including:(a) a base member positioned underneath each lowerresilient layer; said base members each being substantially rigid andhaving an arch curve with a raised heel.
 10. The apparatus of claim 9wherein each upper resilient layer comprises a polyurethane foam layerhaving a tensile strength of between about 14 and 30 psi, a ball reboundresilience value of between about 3.0 and 4.0%, and a thickness of atleast about one inch.
 11. The apparatus of claim 10 wherein said lowerresilient layer of each support pillow member comprises a polyurethanefoam layer having a tensile strength of between about 31 and 40 psi anda ball rebound resilience value of between about 4.1 and 5.0%.